Alternator Welder Runs 120v Power Tools - How To
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- เผยแพร่เมื่อ 19 ส.ค. 2012
- Add the ability to run 120v power tools using your alternator welder with one simple step...
To see welder build...
• Homemade DC Arc Welder...
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Wow! Somebody on you tube with actual brains, I'm impressed!
This was quick, easy to understand and to the point. Thank you for an instructional video that does not just waste everyone's time.
Very welcome.
Ive build some crazy shit in my life, and seen some even crazier shit built, but that is hands down the best mobile shop Ive seen yet.
Haha, thanks!
I just finished watching all of your welder videos. That thing is pretty cool!
+Chip Wright
Thanks. It was a cool project, for sure.
Thank you for opening my eyes to more than I was thinking.
Very welcome, sir. Glad you found the video informative.
Thank you for the reply. Now I understand that your goal was to use minimal parts and money. The machine runs great! I would eventually love to use a similar design to build one for myself. Thanks for sharing!
That MARS comment gave me a good laugh, lol. Thanks. Had it not been for a "mistake" I made while messing around with this welder, I would not have known about it either. I had to go online afterward to find out why it was working, lol.
Thank you Charlie Sarsfield
Thanks for sharing sunny!
ur a frikkin' genius. eye opener for real. appreciate it
Thanks for the compliment. Yes, the alternator was modified. How I did it is shown in my "Homemade DC Arc Welder Build" video. Basically, All that is needed is to bypass the voltage regulator so a full 12-14 volts can be applied to the field circuit of the alternator. Once that is done, the speed of alternator rotation will determine output voltage. Does that clear it up enough? Let me know if you need further explanation.
Brother u earned the mobile wrencher award for sure! nice job!
+Deepblu dude
Hahaha... Awesome!
Nice build man.
This is flat out amazing!
I agree, farmer. You should have seen the look on my face when I figured this out... I was simply wondering if it would work, then tried it, lol.
Thanks for the compliment. Yeah, I'm a big fan of re-purposing, for sure! :)
Very cool! Nice job man!
+Todd Dooley
Thank you!
very nice and clean build. I'm motivated now lol
Go for it!
Keep doing good work man congratulations....
Thanks Romo
Nicely done, thank you.
+Bang Thumper
Very welcome.
Wooo I'm really impressed man thanks. For sharing....
Very Welcome
Only the best Gen Build. Great job!
AWESOME I have no words
Very true, and a great idea actually. :)
I think this is great. I love to see folks "re-purposing" what most consider junk or trash. Imagination and discovery are hallmarks of creative mind. (and can 'geterdone' cheaply!)
The Welder looks Ready for a stroll MARS alongside the Robot.....awesome stuff (I didn't know that about "Universal Motors)
Ja-heez! The only way that rig could be any cooler would be if you could ride it! Way to go Charlie!
+Pa Mil
Thanks. Yeah, I thought about that too, lol.
Thank you.
That's amazing, with US 120V power tools you are so much closer to the full field alternator voltage than with 230 V equivalents. I guess the British construction site 100V or Japanese 110V power tools would work even better!
Just one thought I have: Those switches are not really meant for handling DC so in long run they may end up burning from excessive arcing.
Actually you may be even able to run a computer or a laptop/phone charger out of that DC, as most of those have a switchmode power supply that 1st thing it does is rectify AC to DC, although at higher voltage.
Six years ago ..where you at now? You should have a magnet motor that runs itself by now...good work..don't let anyone tell you it can't be done...
That has been on my list for experiments for years, just haven't had the chance to mess with it yet. Such is life it seems, lol.
That is really news to me that those tools can run on DC being that I am a Industrial Electrician/Mechanic and have worked on motors and controls and automation. I have to point out that running your tools at a lower voltage can drastically reduce the live of your tools. The equation I learned in school was that if you run something (especially a motor with inductive loads) at a %27 (88/120= 27% in your case) percent voltage drop you in turn will reduce the life by %27 also. So the percentages are directly related. The idea being a motor takes a certain amount of wattage and if you reduce the voltage the amperage then needs to make up for that to give you your power(wattage). Less voltage=more amperage=more heat=less motor life.
+ryan guile
Interesting information. I was not aware of this. Thanks for commenting.
Not True Ryan, Not True. He's running on DC (not AC) which gives much greater torque at low speed and compensates for lower volts/higher amp draw scenario.
Have used 'Universal' motors on DC for years with zero problems ! Theory and Practice are often worlds apart !!
I concur with Ryan. Lower voltage on the tools EQUALS EARLY DEATH FOR THE TOOL. Lower voltage equates to higher operating temps [due to higher amps required] in the windings of the tool. There is a reason for math folks. It's not just to piss you off in school. E=IxR no matter what your opinion of it is. And no matter what you think about a motor.
Alex, take a look at this page, it may help you a lot when trying to determine your next reply.
www.sengpielaudio.com/calculator-ohm.htm
dude that cart is totally sick i fkn love it!!!! your mad mad i say hahaha
I have been called that before, lol.
great! thanks for sharing.
You bet!
Yes, all that is very true. Here though, I was going for 120v DC for the tools. My thinking was that you can build a welder that uses only an alternator for welding AND tools, with less components. People already are building alternator welders, so simply adding an electrical outlet to the existing setup, allows for some extra tool usage. Your way however, is the way most people will do it, and that's fine.
rad build! was looking at a 250 amp marine alternator.. got to thinking, gearing it to a two piston scooter gas engine might power off grid needs? confirmation! thanks!
Great video.
Glad you enjoyed it.
this is pertty neat
Very nice. This should easily power a bank of JC's.
You're welcome Adam. When you do build one, make sure to video your build progress and share the results. I know I would like to see it.
Charlie Sarsfield h
This alternator is a Delco 10si. The modification can be seen in my "Homemade DC Arc Welder Build" video. If it's not clear enough, let me know.
Very cool
+Ewing Fabrications
Thanks
nice , i think you could build a "switch" for the alternator controller so you can run the alternator at regulated 12v for charging batteries or whatever with 12 volts and you can also weld ;D
One easy way to get more voltage out of those alternators is to simply rewire the internal three phase stator connections and switch them from the most common Delta (triangle) to a Wye (Y) connection given very few quality made 12 volt alternators use the Wye configuration since it gives more voltage and less current.
Also for a better alternator use a commercial truck or heavy industrial application one. Unlike the common automotive ones, the commercial grade are far more efficient (75 - 85+% Vs 40 - 60% ), over built and can most often run at 100% of their rated power output continuously. Plus most have multiple windings in parallel for each phase that can be reconfigured to give far higher voltages with less RPMs.
I've done a few Leece Neville, Prestolite, and larger case Delco SI series commercial alternator conversions and had no trouble getting them up to 150 - 200 volts outputs at 10 - 20 amps depending on their stock voltage and current ratings while still turning at less than 4000 RPM which makes it possible to actually put regulators on them that will keep their outputs at the wanted 120 VDC or 120 VAC (off the three phase internal connections) without problems.
Best part is that oddly most commerical grade 12 volt 150 - 200 amp alternators cost the same or often less than most stock units of half their capacity. The stock 12 volt 100 amp alternator for my 99 Ford F250 costs considerably more than the Prestolite 12 volt 140 - 160 amp and 24 volt 100 amp continuous rated units (~$130 - $150 new at Napa or through many online dealers) I put on larger farm tractors and commercial construction equipment.
Tcmtech
Having a heavy duty alternator would certainly be ideal. And thanks for the information.
I am thinking of charging three 12 volt batteries off the three phases of the alternator really quickly. Do you think if this could be the fastest way to charge batteries with car alternator? The batteries can take it but there does not seem to be ready made solution for a really quick battery charger (one hour in, one hour out).
DC actually runs incandescent lights and heating elements to the same brightness but at a lower voltage, because you do not have a time when the device is actually switched off 50 times a second.
Careful with running your tools at a lower voltage. You will draw more current through them and burn the tools up.
The windings in a motor rated for 120VAC are much thinner for a given power rating than the ones in a 12v motor.
Yeah, others have mentioned that as well. No issues as of yet though.
I love me some practical machinery!
I can relate! haha
You've said enough. :)
Nice.
Thanks
You bet ya!!!
good stuff ... especially at 4:10 lol
Oh, my twin, lol
yeah lol ... let him do all the not fun work eh? lol
It got high Amps that's why it was running great
Still impressive because I never would have tried it.
The open circuit voltage on most stick welders is about 25 volts DC. You jacked this alternator output up high enough to actually kill you if you touched the stinger and ground clamp at the same time. Just saying. I do like the build and effort you put into the project. Thanks for sharing.
Yes, it packs a punch for sure!
You bet ya!
could you please provide a link to the printout diagram, tanks.
The flo bulbs have a PWM circuit in the base that will put out the needed dc voltage at a large range of input voltage
+ken ezzell
Yeah,figured it was something like that. Thanks for the info.
Is this a Chrysler alternator? Can you tell me how you modified it? Thanks.
Shannon
Amazing video. I only recently gotten into the funny business of "alternator hacking", and I've made a generator so far off of a 7hp Tecumseh engine, and now I wanna use a 8hp Tecumseh and school bus alternator for a welder. I wonder if you Boost the Field Winding voltage if it will keep rising the output voltage, within reason of course (due to heat). Might need to make experimental video soon
Myself playing around, I used a constant 12 to 14 volts for the field winding. I just know that faster you spin the alternator, the greater the output. It would definitely be interesting to see the output of a 24v alternator. Send a link if you do make a video of your experiments.
How has it held up over all this time?
pretty cool. i got an old murray rider i plan to make a similar setup once i get some alternators and fix all 4 tires.
Allen McKinney Awesome! I hope you make a video of your project. let me know if you do, I'd like to see it.
Charlie Sarsfield i may do that. i haven't posted a vid before but ive been thinking of making one of my rc mower.
Allen McKinney I'd like to see that video too, haha. Cool.
Allen McKinney I'd like to see that video too, haha. Cool.
Charlie Sarsfield i plan to shoot some of the rc mower once i get the front wheels back together and i take it to my dads yard. im waiting to get a welder to do the wheels correctly and i dont have much of a yard so im gonna use my dads yard for a demo.
i Like, OLE!
nice bro this is the nices way to run hho generator
+natad libak Haha... Absolutely!
Brother maybe u understand what joe doing in zuzuki video
+natad libak
Funny you mention that. I do understand what he says to a point, but haven't experimented enough to see if what he says is true. I did build a cell somewhat based on his design, but used it to create hydrogen oxygen gas. A video showing me playing with it can be seen here...
th-cam.com/video/qXEGzKHjklE/w-d-xo.html
Its not the joecell bro, the zuzuki video is modification of wiring heactually remove the positive wire in the car but still going and he switch off the key of the car but still runing the car
+natad libak
Precisely!
Who needs light while striking an arc anyway? Seems like a good project.
+zappy bear
Haha. Yeah, it was a fun build project.
Am I the only one who noticed that the #10 wire that's good for 30 amps and fused a 30 amps is feeding a receptacle that's only good for 20 amps at best. Can you say POOOOOFFF!!!
+Reagan Rogers
Don't know if you are the only one that noticed, but you are the only one who said anything, haha. It's all good.
Charlie Sarsfield When I first looked at the diagram I was like WTF. And after seeing all the shit he was running off of it I was really like WTF!!! Hope he has fire extinguisher close by.
+Reagan Rogers
Always have extinguishers in the garage. I do some crazy stuff sometimes, lol.
First thing I noticed was the 15 amp receptacle fed by 30 amps.
+Christopher's Customs
Yeah, I will make a correction on the video some how. At the time of the build (5ish yrs ago) I calculated the fuse rating thinking in watts. It's a 12v 30a DC fuse, but I was calculating with around 90vdc. I know now that's NOT the way to do it.
nice, i wonder how many can be run in series for induction heater?
+Leslie Jones Interesting idea. I have no idea if that's even possible.
i heard you have to have a lightening
protector case
+Leslie Jones I have no idea. If you figure it out, let me know. Or better, you do a video on it.
Best heat is a. 100w light bulb most are banned but its perfect for low watt heat they also make heater that is 12v and 160w you would need a bunch tho to heat a big area
Great conversion. Im assuming this is a permanent magnet alternator? Also hows it holding up in 2020 as a welder and general use with this alternator in the video?
The alternator is a standard type from my old Jeep. The tractor's battery supplied the input voltage.
I took some parts from this project for another awhile back, so it's not currently usable. Never had any problems with it while it was together though.
Got to wonder how many loads will it handle at one time.
Oh how many alternater generators under full load will the engine drive.
120 ÷12 vlt = 10 inverters running correct ac sinwave for ac only appliances.
hola buen,dias amigo una pregunta alternator puede 110v y bombillo 60n w o 100 la casa la luz sy venezuela
damn...I need a welder to build my alternator welder.
Can you comment on running 18v tools? I thought it was in this video but re-watching appears it was another on the weldernator subject. Can anyone point me to how that would be done? I have some 18v dead tools. Thanks for the video Charlie!
Though i haven't tried it, you can probably connect the tool directly to an un-modified alternator putting out the standard 12 - 14 volts. You won't get the 18v,but this is probably the easiest path.
add a couple large caps so you got reserve for starting bigger tools..just thought it might work for you
+Jason Ross
Thanks for the input.
yeah i would use a few microwave caps..they are good at keeping even current..hope it helps. oh and if you take them from used microwaves need to ground them out to dicharge, there is enough stored power in them even after they have ben unpluged for a while, they can kill you if they make contact with you if not discharged but most people know this lol i just had to add that sop if some one didnt then this might save them from getting bit :)
+Jason Ross
Thanks again, and thank you for throwing in the warning for others to see.
Can you try build a generator without engine, you connect alternator to something strong like AC or DC, it spins alternator, powers to other motor.
Absolutely you can build a generator without an engine. Just depends on your end goal. I've used an AC motor to turn an alternator for battery charging. Used an AC motor to turn a modified alternator for hydrogen experiments and even connected two alternators via their 3-phase stators.... turning one of them into a motor. All for good ole fun. :)
Oh lol xD I wish I had an alternator, but I have some big motors that are brushless, running at 850 RPM i think 1HP, i dont know how strong is 1 HP.
@@breezetix ~749 Watts
Yeah most power tools will run on AC or DC funny they will last longer run cooler and be more powerful on DC lol. Induction AC motors like drill press table saws will not run on DC but the brushess are what to look for he's right. I love mine didn't spend but 80 $ I built a much bigger rectifier using industrial forklift charger diodes. BTW most of those small air compressors you know the ones that make more noise that a dump truck driving thru a nitro glycerin plant will run off DC I use mine all the time 😁
can you show me how to wire it up sir thank you for your time
Yes, in the description is a link to my build video.
Hey, nice video. Did you say this is a 120 DC Volts? how do you step up your DC from around 14VDC to 120V DC? Can you clarify on that? did you modify your alternator?
It looks like the alternator's OPEN circuit voltage when bypassed the regulator is very high. The reason this does not blow up your car battery is the regulator, which just turns the alternator into a "constant current source", and detects when it is outputting too much power, then lowers it.
Two alternators in series?
Naaa, I'm just lucky! :) Glad you enjoyed it.
how do i know what fuse i need,
Why does the light turns off every time you start to weld? Aren't you using a inverter?
Miguel Ángel Valderrama Because the welding sucks all the juice,lol. No, it's all powered by alternator DC. Link in description to the build video.
Nice instructional, but you need to ditch the obnoxious music, in fact, why any music at all?
What is the thickness of Rod that you use and what is the thickest you've used
3/32 is what i had on hand and is the biggest I've tried.
Why not use a 110v electric motor with a pulley system run to two alternators that run the current together to a breaker box and run power back to the 110 volt motor plus have lots of power left over? You can also use a starter to start it up just add a secondary set of wires from the alternator to One battery to keep it charged for your starter. And run wires from the battery to a push button starter and you got it whipped.
Naaa, that's just how I did it since I had one. It could have easily been built without using one. :)
Nice build!
If you want to get the full 120 volts AC, you can install an inverter into the chassis of your generator. You have a 12 volt input from an alternator, and it converts that into 120 volts AC out. Make sure you get one that has enough wattage to fit your needs though.
Have you thought about hooking up your alternator to an electric motor and using it to run your house? I mean if you can weld with it it would probably run everything.
Ha, no. It's the wrong type of juice for that.
If you take out the parts that make it DC it changes your power to AC should be able to work
True, but the ac frequency is about doubled compared to standard household input, so i haven't really experimented much with the ac side.
you have any video on making that mobile shop.
Jim Cady Yes. Link is in description.
I have watched it just wonder if a smaller gas engine 6.5 hp would be enough power to turn that alternator to make welder?
Not sure on that one, as I haven't tried it.
+Jim Cady I hope I'm not intruding here but the setup that I have at my house is a 10000 watt self exciting generator it has a RMS of 7400 watts continuous and it is written in explicit details that you have to have an 11 horsepower gas motor to turn this generator well I've been lied to my entire life by the electric companies and everybody else so why wouldn't I try a 1 & a half horsepower Farm Duty compressor motor and guess what not only did it turn one 10000 watt generator it turned two and without a load breakdown!! so don't believe anything you were taught in school unless you know a hundred percent that it's true it works and there's no other way to do it and then it's probably still a lie... keep up the good work guys!!!
You weld with the same voltage for the alternator
Yes, and that voltage can be varied depending on speed and/or voltage input.
What is the Hertz it's putting out on the AC side??? Wrong Hertz (HZ) will definitely blow out electronics and some motors.
Not exactly sure of the AC Hz, but it's crazy high. I only use the AC side for lightbulbs. Definitely don't want to connect electronics or AC motors to this thing. I use it for DC welding and universal motors on the DC side.
There is more power contained in DC current than the same voltage of AC current. RMS.
+Ray Conger
Thanks for the input. Yeah, I can see how that would be so.
Ray Conger
Does this mean high voltage can compensate for little to no amperage.
How long did it take to boil water,??when you’re a boat person,it’s important
Honestly I cannot remember. You'll have to experiment with that one.
Get another riding lawnmower or like a go kart or something and turn that homemade kart you built into a trailer!!!
+Tim Groot
Sounds like a good plan. ☺
how did you do the ac side?
James Flores Connected two of the three alternator phases to an electrical outlet. One on hot side and the other to neutral. For me, it didn't yield useful results compared to using the DC output. Be careful if you mess with it. stay safe.
did you keep the diodes from the stock alternator
James Flores took out the trio diode and capacitor. The Homemade welder build video i did shows the alternator mods, which aren't many. For the ac, I just connected the outlet wires where the stator connects to the rectifier. two of them, not all 3.
will watch the vid
No entiendo,el alternador es trifasico,(3 cables de salida) que hizo con ellos ,los unio en uno solo ,no entiendo.
Yes, the alternator is 3 phase, and the output diode is still intact and functional. The output is still DC. The only real manipulation is removing the regulator and controlling input voltage/current to the rotor windings.
Ok, entiendo gracias.
How much will you sell the schematics for????????????????????
Markus Daniels Link in description to my other video which goes through the alternator mod AND the complete build with schematic. Free of charge! ☺
Todo eso con el alternado no lo creo si el alt vota 12 si tiene 1 conversor si
+Guido Hernan Zamora Velez
A link in the description will take you to a previous video where I modified the alternator to bypass the voltage regulator. That is the only modification required. I used no external converter.
Guido Hernan Zamora Velez si le quitas el regulator de voltaje puede generar mucho mas de 120v dependiendo de el rpm de el alternador
Try adding another alternator
+Lucas Hein
That has crossed my mind. I definitely have the hp to do it.
like your job but hate your introduction music it cause a headach
+ABU. HAMDAN Thanks. Yeah, the music isn't for everyone.
hey Charlie it's not very often people find things out on their own like this and I've known about this for about well let's just say a long time... Yahweh (god) has instructed me to guide you and everyone else with the correct knowledge. so with that being said if you want it to produce alternating current with a stable sine wave you need an alternating current Bridge rectifier which means you will have to have a capacitor and a mosfet for timing you're going to need about twenty seven volts on your left terminal and 115 on your right terminal but don't worry about any of that because the alternating current Bridge rectifier will produce that and it will be a self exciting generator just like the magnetic field that it produces on the stator for the direct current generator there is no difference between an alternator a generator and a motor except for how you wire them up or use them... hope this helps you out so go buy you an alternating current Bridge rectifier from a small engine shop you'll be glad you did!!
Thomas Buie you say to produce AC current you need a Bridge Rectifier. I only know a Bridge Rectifier to produce DC current from AC current. Does it work both ways or something? Would you or someone please clarify. Thanks.
No he's just a wannabe, rectifiers don't produce AC from DC. Doesn't know his ass or his elbow.
S. E that's what I thought. Thanks
I've only seen Rectifiers that convert AC to DC. However there are ways to make DC run kinda like AC but instead of a sine wave it's a square wave, this is own as an inverter. This can cause more issues with motors that are made for AC.
Alternators produce AC anyway, single phase or three phase AC at that. There is a built in high amp bridge rectifier and voltage regulator. If you can find a way to tap into a altenator before the bridge rectifier and find a way to regulate the voltage since the built in regulator is for DC then you will be good to go. A variac would work for a AC voltage regulator but for power tool use you would need a high amp model, might just be easier to find out the perfect pulley size and RPMs the altenator needs to spin to get around 110v to 120v. If I remember a lot of older Ford altenators from the 70s and older have taps already to bypass the bridge rectifier.
Another idea would be using two Altenators in series tossing out 55 to 60 volts each.
Thomas Bui
Wire Diagram please. Please.
+Oswaldo f
Link in description to the build video. Includes full wiring diagram.
With that kind of voltage do you need any kind of special _welding rod?_
+faffaflunkie
Nope, just standard rods. Not sure of a minimum voltage for welding. In the video I was running 88V, but some folks are welding with half that via car batteries in series. Its more the available current than voltage.
Open circuit voltage should be at least 36 volts. Lower and you might get stuck rods.
Pay Way
Thanks for that information.
y ur light go out win u weld
jay smoker The welding sucked all the juice.
'Under voltage kills' ,equipment that is.
+james jackson
That's what i keep hearing, but it's not what I'm experiencing with these universal ac/dc motors.
under voltage kills switched loads, sensitive loads, not ac/dc brush motors or light bulbs, james!